Dip molded wire connector

Abstract

A connector with a dip-molded housing and a method for forming a twist-on wire connector with a dip-molded housing. To dip-mold a covering or housing on a twist-on wire connector either a mandrel carrying a twist-on wire coil, a mandrel having the a shape of a spiral coil or a twist-on wire connector are dipped into a bath of an in situ solidfiable dip-moldable material such as liquid plastic. The dip-moldable solidified material solidifies to form a dip-molded shell on the wire connector.

1. A twist-on wire connector having enhanced impact resistance comprising;
 a spiral wire coil having an internal surface with a female spiral thread and an external surface with a male spiral thread; and 
 a one-piece dip-molded shell having a female thread for mating with the male spiral thread of the wire coil for retaining the wire coil therein comprising a layer of shock absorbing insulating material, said shock absorbing insulating material comprising a soft-to-the-touch non-slip dip-moldable material having a shape conforming to an external surface of the male spiral thread to thereby cushion any impact to the twist-on wire connector, said dip-molded shell extending radially past an end of the wire coil. 
 
   
   
     2. A twist-on wire connector having enhanced impact resistance comprising;
 a rigid housing having an interior surface and an exterior surface; 
 a wire engaging member located on said interior surface of the rigid housing; and 
 a soft-to-the-touch, non-slip, one-piece dip-molded shell secured to and entirely covering the exterior surface of the rigid housing with the dip-molded shell softer than the rigid housing to thereby provide a twist-on wire connector with enhanced impact resistance, said dip-molded shell having an internal surface shape and an annular lip for retaining the rigid housing therein, said soft-to-the-touch, non-slip, dip-molded shell extending radially past an end of the rigid housing and the annular lip. 
 
   
   
     3. The twist-on wire connector of  claim 2  wherein the dip-molded shell comprises plastisol. 
   
   
     4. The twist-on wire connector of  claim 2  wherein the dip-molded shell has a thickness of at least 0.020 inches. 
   
   
     5. The twist-on wire connector of  claim 2  wherein the dip-molded shell upon solidification has a durometer of less than 80. 
   
   
     6. The twist-on wire connector of  claim 2  including radially inward extending pie shaped segments that are circumferentially spaced from each other. 
   
   
     7. The twist-on wire connector of  claim 2  including a sealant chamber located proximate an end of the twist-on wire coil. 
   
   
     8. The twist-on wire connector of  claim 2  including compressible air pockets on the housing of the wire connector to thereby provide a wire connector with enhanced comfort grip.